Installation and maintenance LSRPM - PLSRPM. Permanent magnet synchronous motors. Référence : 4155 en / g

Transcription

1 Permanent magnet synchronous motors Référence : 4155 en / g

2 IMPORTANT These symbols appear in this document whenever it is important to take special precautions during installation, operation, maintenance or servicing of the motors. It is essential that electric motors are installed by eperienced, qualified and authorized personnel. In accordance with the main requirements of EEC Directives, the safety of people, animals and property should be ensured when fitting the motors into machines. Particular attention must be given to equipotential ground or earthing connections. The following preliminary precautions must be taken before working on any stationary device: Mains voltage disconnected and no residual voltage present Careful eamination of the causes of the stoppage (jammed transmission - loss of phase - cut-out due to thermal protection - lack of lubrication, etc) Even when not supplied with power, there is voltage at the terminals of a rotating synchronous motor with magnets. Accordingly, before carrying out any work check carefully that the motor is not rotating. For dismantling the permanent magnet motor only Assembly or maintenance of the rotor must not be carried out by people with pacemakers or any other implanted medical electronic device. The motor rotor contains a powerful magnetic field. When the rotor is separated from the motor, its field can affect pacemakers or disturb digital devices such as watches, mobile phones, etc. 2

3 Dear Customer, You have just acquired a Leroy-Somer motor. This motor benefits from the eperience of one of the largest manufacturers in the world, using state-of-the-art technologies automation, specially selected materials and rigorous quality control. As a result, the regulatory authorities have awarded our motor factories ISO 9001, Edition 2008 international certification from the DNV. Similarly, our environmental approach has enabled us to obtain ISO 14001: 2004 certification. Products for particular applications or those designed to operate in specific environments are also approved or certified by the following organizations: CETIM, LCIE, DNV, ISSEP, INERIS, CTICM, UL, BSRIA, TUV, CCC, GOST, which check their technical performance against the various standards or recommendations. We thank you for making this choice, and would ask you to read the contents of this manual. By observing a few essential rules, you will ensure problem-free operation for many years. CE conformity Leroy-Somer NOTE: Leroy-Somer reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments. The information contained in this document may therefore be changed without notice. Copyright 2003: Leroy-Somer Motors This document is the property of Leroy-Somer. It cannot be reproduced in any form without prior authorization. All brands and models have been registered and patents applied for. 3

4 CONTENTS 1 - RECEIPT Identification Storage POSITION OF LIFTING RINGS ASSEMBLY AND COMMISSIONING RECOMMENDATIONS Checking the insulation Location - ventilation Coupling Motor protection Connections COMMISSIONING THE VARIABLE SPEED DRIVE ROUTINE MAINTENANCE Checks Bearings and lubrication Bearing maintenance PREVENTIVE MAINTENANCE TROUBLESHOOTING GUIDE SPARE PARTS

5 1 - RECEIPT On receipt of your motor, check that it has not suffered any damage in transit. If there are obvious signs of damage, contact the carrier (you may be able to claim on their insurance) and after a visual check, turn the motor to detect any malfunction Identification As soon as you receive the motor, check that the nameplate on the machine conforms to your order. Definition of symbols used on nameplates: Legal mark of conformity of product to the requirements of European Directives. 3 ~ : Three-phase AC motor LSRPM : Series 200 : Frame size L : Housing designation and manufacturer code TC : Impregnation inde Motor : Motor serial number B : Month of production 15 : Year of production 001 : Batch number IP55 IK08 : Protection inde Ins. cl. F : Insulation class F Ta 40 C : Ambient operating temperature S : Duty % : Operating factor 1000m : Maimum altitude without derating kg : Weight RI DE NDE : Insulated bearing : Drive end bearing : Non drive end bearing 12 g : Amount of grease at each regreasing 2200 h : Regreasing interval (in hours) for the ambient temperature (Ta) QUIET BQ : Type of grease A H : Vibration level : Balancing mode Inverter settings : Parameters to be entered in the drive EMF (v/kmin -1 ) : Electromotive force Lq/Ld % : Cogging ratio min.fsw (khz) : Minimum switching frequency Ima/In %: Maimum current ratio/rated current V : Voltage Hz : Supply frequency min -1 : Revolutions per minute pol. : Number of poles Ld (mh) : Transient inductance A : Rated current Motor performance : Motor characteristics V : Voltage Hz : Supply frequency min -1 : Revolutions per minute kw : Rated power Eff % : Efficiency A : Rated current Inverter mains supply (v) : Drive mains supply voltage Nma (min -1 ) : Maimum speed 5

6 1.2 - Storage Prior to commissioning, machines must be stored: - Protected from humidity: at relative humidity levels above 90%, the machine insulation can drop very quickly and become virtually non-eistent at around 100%. The state of the anti-rust protection on unpainted parts should be monitored. For prolonged storage longer than 3 months, place the machine in a sealed waterproof covering (for eample heat-shrunk plastic) containing sachets of desiccant corresponding to the volume and the degree of humidity of the location: - Away from frequent significant variations in temperature, to avoid the risk of condensation. During storage the drain plugs must be removed to allow condensation water to escape (provided at the lowest point, depending on the operating position). This location must be dry and protected from harsh weather conditions, cold (temperature between 15 C and + 80 C), free from vibration, dust and corrosive gases. - If the area is subject to vibration, try to reduce the effect of this vibration by placing the motor on a damping support (rubber plate or similar). Turn the rotor a fraction of a turn once a fortnight to prevent the bearing rings from becoming marked. - Do not remove the rotor locking device (where there are roller bearings). Even if the motor has been stored in the correct conditions, certain checks must be carried out before it is started up: Greasing Bearings which cannot be regreased Maimum storage: 3 years. After this time, replace the bearings. Bearings which can be regreased Storage period Grade 2 grease less than 6 months more than 6 months less than 1 year more than 1 year less than 5 years more than 5 years Grade 3 grease less than 1 year more than 1 year less than 2 years more than 2 years less than 5 years more than 5 years The motor can be commissioned without regreasing Regrease before commissioning, as described in section 5.2 Dismantle the bearing - Clean it - Replace the grease completely Change the bearing - Regrease it completely Greases used by Leroy-Somer: see nameplate 2 - POSITION OF LIFTING RINGS Position of lifting rings for lifting the motor only (not connected to the machine). Labour regulations stipulate that all loads over 25 kg must be fitted with lifting devices to facilitate handling. The positions of the lifting rings and the minimum dimensions of the loading bars are given below in order to help with preparation for handling the motors. If these precautions are not followed, there is a risk of warping or crushing some equipment such as the terminal bo, cover or drip cover. Motors intended for use in the vertical position may be delivered on a pallet in the horizontal position. When the motor is pivoted, the shaft must under no circumstances be allowed to touch the ground, as the bearings may be irreparably damaged. Moreover, additional special precautions must be taken, as the integral motor lifting rings are not designed for pivoting the motor. Horizontal position h A e 2 Øt Type Horizontal position (mm) A e min h min Øt 100 L M MP/LR L/L1/L LU/LU ST1/ST2/MR1/SR SG MY SE/SE1/ME/ME SC/SC1/SD/SD1/ SCM/MD MK SN SP1/MP1/MR LD

7 Vertical position C h e 3- ASSEMBLY AND COMMISSIONING RECOMMENDATIONS In all cases, compatibility of the motor and its environment must be guaranteed before its installation and also throughout its life. E n ØS D Electric motors are industrial products. They must therefore be installed by qualified, eperienced and authorized personnel. The safety of people, animals and property must be ensured when fitting the motors into machines (please refer to current standards). View from above Side view Type Vertical position (mm) C E D n** ØS e min* h min 200 L/L1/ L LU/ LU ST1/ ST2/MR1/ SR2 225 SG MY SE/ SE1/ME/ ME1 280SC/ SC1/SD/ SD1/SCM/ MD MK SN SP1/ MP1/MR * If the motor is fitted with a drip cover, allow an additional 50 to 100 mm to avoid damaging it when the load is swung. ** If n = 2, the lifting rings form an angle of 90 with respect to the terminal bo ais. If n = 4, this angle becomes Checking the insulation Before starting the motor, check the insulation between the phases and earth. This check is essential if the motor has been stored for longer than 6 months or if it has been kept in a damp atmosphere. This measurement must be carried out using a megohmmeter at 500 V DC (do not use a magnetoelectric system). It is better to carry out an initial test at 30 or 50 volts and if the insulation is greater than 1 megohm, carry out a second test at 500 volts for 60 seconds, between the winding and earth (use any motor terminal). The insulation value must be at least 10 megohms in cold state. If this value cannot be achieved, or if the motor has routinely been splashed with water or salt spray, or kept for a long period in a very humid place, or if it is covered with condensation, the motor should be dried using the optional space heaters if the motor has them (see section 3.4.3) or follow the methods described below. Do not apply the megohmmeter to the terminals of the thermal sensors as this can damage them. Drying using eternal heating - Place the motor in an oven at 70 C for at least 24 hours until the correct insulation is obtained (100 MΩ). - Take care to increase the temperature gradually to clear the condensation. - After drying at ambient temperature during the cooling phase, check the insulation value regularly, as it will initially tend to fall then rise. 7

8 Drying using internal heating Winding connections for drying using internal reheating U1 I dc < 50% In U dc V1 W1 - Connect motor windings V1 and W1 in parallel in relation to U1. - Read off the resistance between U1 and V1/W1. - Apply a low voltage DC current to them (to obtain 10% of the rated current calculated using the winding resistances), then increase the voltage until 50% of the rated current is reached. - Maintain the power for 4 hours. The temperature of the motor should increase slightly. - NB: The DC current must be monitored using a shunt ammeter. This current must not eceed 60% of the rated current. It is advisable to place a thermometer on the motor housing: If the temperature eceeds 70 C, reduce the indicated voltage or current by 5% of the original value for every 10 difference. While it is drying, all the motor orifices must be open (terminal bo, drain holes) Location - ventilation The motor must be installed in a ventilated place, with clearance for the air inlet and outlet. Obstruction (clogging) - even accidental - of the ventilation circuit has an adverse effect on motor operation. With drip-proof motors, do not obstruct the air inlet with a coupling guard, provide a perforated plate. It is also necessary to check that the hot air is not being recycled. If it is, pipes must be provided for the intake of cold air and epulsion of hot air, in order to prevent abnormal motor temperature rise. In this case, if the air is not circulated by an auiliary fan, the dimensions of the pipes must be such that the pressure losses are negligible compared to those of the motor TEFV motors Our motors are cooled in accordance with method IC 411 (standard IEC 34-6) i.e. machine cooled by its surface, using the ambient fluid (air) flowing along the machine. The fan at the non-drive end cools the motor. Air is sucked in through the grille of a fan cover (which provides protection against the risk of direct contact with the fan in accordance with standard IEC 34-5) and blown along the housing fins to ensure thermal equilibrium of the motor whatever the direction of rotation. 1/4 H min M H Warning: If the high voltage test which was carried out at the factory before shipping needs to be repeated, it should be performed at the voltage: 0.8 (2U V). Check that the capacitive effect resulting from the high voltage test is eliminated before connecting the terminals to earth. The heating solution by AC injection must not be used Drip-proof motors Our motors are cooled in accordance with method IC 01 (standard IEC 34-6), ie. machine cooled by means of the ambient fluid (air) circulating inside the machine. A fan at the non-drive end cools the motor. Air is sucked in at the motor drive end and blown along the fan cover to ensure thermal equilibrium of the motor whatever the direction of rotation. Ø H ma Air inlet H 8

9 Positioning The motor must be mounted in the position specified on the order, on a base which is rigid enough to prevent distortion and vibration. Where the motor feet have si fiing holes, it is preferable to use those which correspond to the standard dimensions for the motor power rating (refer to the motors technical catalogue) or, should this not be the case, to those shown at B2. Provide easy access to the terminal bo, the condensation drain plugs and, if appropriate, to the grease nipples. Use lifting equipment which is compatible with the weight of the motor (indicated on the nameplate). When the motor is fitted with lifting rings, these are for lifting the motor on its own. They must not be used to lift the whole machine after the motor has been fitted to it. Note 1: When installing a suspended motor, it is essential to provide protection in case the fiing breaks. Note 2: Never stand on the motor. B 1 B Standard slide rail option (conforming to standard NFC ) These steel slide rails are supplied with tension screws and 4 nuts and bolts for fiing the motor onto the slide rails, but the fiing bolts for the slide rails are not supplied. X Z Y H ØJ L A E K Motor Type of Dimensions Weight per pair frame size slide rail A E H K L X Y Z Ø J of slide rails (kg) 90 G 90/8 PM and 132 G 132/10 PM G 180/12 PM and 225 G 225/16 PF and 280 G 280/20 PF G 355/24 PF

10 3.3 - Coupling Preparation Rotate the motor before coupling to detect any possible fault due to handling. Remove any protection from the shaft etension. Note: the rotor magnets generate resistance to rotation. CONFORMING MOUNTINGS Coupling adapted to the Machining of visible parts length of the key protruding from the key Part to be machined NON-CONFORMING MOUNTINGS Non-machined open keyway. Coupling not adapted to the length of the key Drain off any condensation water that has formed inside the motor be by removing the plugs from the drain holes. Rotor locking device For made-to-order motors with roller bearings, remove the rotor locking device. In eceptional circumstances when the motor has to be moved after the coupling device has been fitted, the rotor must re-immobilized. Balancing Rotating machines are balanced in accordance with standard ISO 8821: - Half-key when the shaft etension is marked H - No key when the shaft etension is marked N - Full key when the shaft etension is marked F Any coupling element (pulley, coupling sleeve, slip-ring, etc) must therefore be balanced accordingly. To find out the motor balancing, refer to its nameplate. The motors are balanced with ½ key as standard unless otherwise indicated. The coupling balancing therefore needs to be adapted to the motor balancing, and the coupling needs to be adapted to the length of the key or the visible parts protruding from the key need to be machined. A customized key can be used. Failure to adhere to these recommendations can lead to premature wear of the bearings and invalidate the statutory warranty. If a motor is started up without a coupling device having been fitted, carefully immobilize the key in its housing. Beware of backdriving when the motor is switched off. The appropriate precautions must be taken: - For pumps, a non-return valve must be installed. - For mechanical devices, install a backstop or a holding brake. - Etc. Tolerances and adjustments The standard tolerances are applicable to the mechanical characteristics given in our catalogues. They comply fully with the requirements of IEC standard Users must adhere strictly to the instructions provided by the transmission device supplier. - Avoid impacts which could damage the bearings. Use a spanner and the tapped hole of the shaft etension with a special lubricant (e.g. molykote grease) to make it easier to fit the coupling. The hub of the transmission device must be: - Fully in contact with the shoulder of the shaft or, if this is missing, against the metal stop ring which forms a labyrinth seal and thus locks the bearing in place (do not crush the seal). - Longer than the shaft etension (2 to 3 mm) so that it 10

11 can be tightened using a screw and washer. If it is not, a spacer ring must be inserted without cutting the key (if this ring is large, it must be balanced). Direct connection using a rigid coupling sleeve Both shafts must be aligned so as to adhere to the tolerances of the coupling sleeve manufacturer. Maintain the minimum distance between the shaft etensions to allow for epansion of the motor shaft and the load shaft. Applied to shoulder of shaft Applied to stop ring Ø A Ø (mm) A (mm) min 28 to to 85 2 Inertia flywheels must not be mounted directly onto the shaft etension, but installed between end shields and connected by a coupling sleeve. Direct connection onto the machine When mounted directly on the motor shaft etension of the moving device (pump or fan turbine), check that this device is perfectly balanced and that the radial force and the aial thrust are within the limits indicated in the catalogue for bearing performance. Direct connection using a fleible coupling sleeve Selection of the coupling sleeve should take account of the rated torque to be transmitted and the safety factor dependent on the starting conditions for the electric motor. The machines must be carefully aligned, so that any lack of concentricity and parallelism in the two coupling halves is compatible with the recommendations of the coupling sleeve manufacturer. The two parts of the coupling sleeve should be provisionally assembled to make it easier to alter their relative position. Adjust the parallel plane of both shafts using a gauge. Measure the distance between the two coupling surfaces at one point on the circumference. Rotate them 90, 180 and 270 in relation to this initial position, and measure each time. The difference between the two etreme values of dimension must not eceed 0.05 mm for standard couplings. Transmission via belt pulleys (up to Series 2400) The user can choose the diameter of the pulleys. Positioning the belts So that the belts can be correctly positioned, allow for possible adjustment of approimately 3% with respect to the calculated distance E. Force must never be used when fitting the belts. For notched belts, position the notches in the pulley grooves. E Pulley alignment Check that the motor shaft is completely parallel with that of the receiving pulley. Protect all rotating devices before power-up. To perfect this adjustment and at the same time check the concentricity of the two shafts, fit 2 gauges as shown in the diagram and slowly turn both shafts. The differences registered by either shaft will indicate the need for an aial or radial adjustment if the difference eceeds 0.05 mm. 11

12 Adjusting the tension of the belts The tension of the belts must be adjusted very carefully in accordance with the recommendations of the belt supplier and the calculations made when the product was specified. Reminder: - Tension too great = unnecessary force on the end shields which could lead to premature wear of the bearing unit (end shield-bearings) and eventually break the shaft. - Too little tension = vibration (wearing of the bearing unit). Fied distance between centres: Place a belt tensioning pulley on the slack side of the belts: - Smooth pulley on the outside of the belt - Grooved pulley on the inside of the belts when using V-belts Adjustable distance between centres: The motor is usually mounted on slide rails, which enables optimum adjustment of the pulley alignment and the belt tension. Place the slide rails on a completely horizontal baseplate. The lengthways position of the slide rails is determined by the length of the belt, and the crossways position by the pulley of the machine being driven. Mount the slide rails firmly with the tension screws in the direction shown in the diagram (the slide rail screw on the belt side between the motor and the machine being driven). Fi the slide rails onto the baseplate and adjust the belt tension as before. Tension screw Motor protection Recommendations for variable speed Special precautions must be taken when using synchronous motors powered via a frequency inverter: During prolonged operation at low speed, cooling efficiency is greatly reduced. A forced ventilation unit should therefore be installed that will produce a constant flow of air independently of the motor speed. Caution: Make sure you comply with the supply voltages specified on the motor rating plate (± 10%). Outside this range, there is a risk of temperature rise Thermal protection The motors are protected by the variable speed drive, placed between the isolating switch and the motor. Adjusting the thermal protection It must be set to the value of the current shown on the motor nameplate for the voltage and frequency. The drive provides total protection of the motor against mechanical overloads. Built-in indirect thermal protection The motors are fitted with PTC sensors as standard. As an option specific sensors (see table overleaf) can be fitted on the motor to monitor temperature changes at hot spots : - overload detection - cooling check - monitoring strategic points for maintenance of the installation It must be emphasized that under no circumstances can these sensors be used to carry out direct regulation of the motor operating cycles. Motor PTC sensors must be connected in order to maintain optimum protection. Tension screw 12

13 Type Operating principle Operating curve Breaking capacity (A) Protection provided Mounting Number of devices* Normally closed thermal protection PTO Bimetallic strip, indirectly heated, with normally closed (NC) contact I O T NRT 2.5 A at 250 V with cos j 0.4 general surveillance for non-transient overloads Mounting in control circuit 2 or 3 in series Normally open thermal protection PTF Bimetallic strip, indirectly heated, with normally open (NO) contact I F NRT T 2.5 A at 250 V with cos j 0.4 general surveillance for non-transient overloads Mounting in control circuit 2 or 3 in parallel Positive temperature coefficient thermistor PTC Temperature sensor KT Υ Thermocouples T (T < 150 C) Copper Constantan K (T < 1000 C) Copper cupronickel Platinum resistance thermometer PT 100 Non-linear variable resistor, indirectly heated Linear variable resistor, indirectly heated Peltier effect Linear variable resistor, indirectly heated R R V R NRT T T T T general surveillance for transient overloads high accuracy continuous surveillance of key hot spots continuous surveillance of hot spots at regular intervals high accuracy continuous surveillance of key hot spots Mounted with associated relay in control circuit 3 in series Mounted in control boards with associated reading equipment (or recorder) 1 per hot spot Mounted in control boards with associated reading equipment (or recorder) 1 per hot spot Mounted in control boards with associated reading equipment (or recorder) 1 per hot spot - NRT: nominal running temperature - The NRTs are chosen according to the position of the sensor in the motor and the temperature rise class. * The number of devices relates to the winding protection. Alarm and early warning All protective equipment can be backed up by another type of protection (with different NRTs). The first device will then act as an early warning (light or sound signals given without shutting down the power circuits), and the second device will be the alarm (shutting down the power circuits). Warning: The motor can remain poweredup, depending on the type of protection. Ensure that the mains supply is disconnected before any work is carried out in the terminal bo or in the drive cabinet Protection against condensation: space heaters option Marking: 1 red label A glass fibre fleible resistor is fied on 1 or 2 coil end turns. This resistor heats the machines when stopped and thus prevents condensation inside the machines. Power supply: 230 V single-phase unless otherwise specified by the customer. If the drain plugs at the bottom of the motor were not removed at the time of installation, they must be opened approimately every 6 months. Warning: Check that the space heaters are powered down before any work is carried out in the terminal bo or in the drive cabinet. 13

14 Reinforced insulation Standard motors are compatible with power supplies with the following characteristics: U rms = 480 V ma. Value of voltage peaks generated at the terminals: 1500 V ma. However, they can be supplied under more severe conditions if additional protection is provided. Reinforced winding insulation The main effect associated with supplying power via an electronic drive is overheating of the motor due to the non-sinusoidal shape of the signal. In addition, this can result in accelerated ageing of the winding through the voltage peaks generated at each pulse in the power supply signal. For peak values greater than 1500 V, a super-insulation option for the winding is available over the entire range. Mains voltage Cable length Frame size Winding protection < 20 m All frame sizes Standard* 480 V > 20 m < 315 Standard* and < 100 m 315 RIS or drive filter** < 250 Standard* > 480 V < 20 m 250 RIS or drive filter** and 690 V > 20 m and < 100 m < 250 RIS or drive filter** 250 RIS or drive filter** *Standard insulation = 1500 V peak and 3500 V/ms ** RIS: Reinforced insulation system. Do not use a drive filter in Sensorless mode. Reinforced insulation of the mechanical parts Supplying power via a drive can affect the mechanical parts and can lead to premature wear of the bearings. This is because, in any motor, a shaft voltage eists with respect to earth. This voltage, due to electro-mechanical dissymmetries, creates a potential difference between the rotor and the stator. This effect can generate electrical discharges between balls and slip-rings and lead to a reduction in bearing life. If power is supplied via a PWM drive, a second effect is added: high-frequency currents generated by the IGBT output bridges of the drives. These currents attempt to spread towards the drive and therefore flow through the stator and via earth where the link between the casing, machine frame and earth is correctly made. Some motors are equipped with insulated bearings as standard, see section If the earth connection cannot be relied on, an insulated bearing option is available over the entire range from frame size 200. For instructions on connecting the motor to earth, refer to section Connections Prior to commissioning for all motors: Rotate the motor at no load (no mechanical load) for 2 to 5 minutes, checking that there is no abnormal noise. If there is any abnormal noise, see section Variable speed drive environment Influence of the mains supply Each industrial power supply has its own intrinsic characteristics (short-circuit capability, voltage value and fluctuation, phase imbalance, etc) and supplies equipment some of which can distort its voltage either permanently or temporarily (notches, voltage dips, overvoltage, etc). The quality of the mains supply has an impact on the performance and reliability of electronic equipment, especially variable speed drives. Emerson Industrial Automation drives are designed to operate with the mains supplies typically found on industrial sites throughout the world. However, for each installation, it is important to know the characteristics of the mains supply so that you can take corrective steps in the event of abnormal conditions. Transient overvoltages There are numerous sources of overvoltages on an electrical installation: Connection/disconnection of banks of power factor correction capacitors High-power thyristor-controlled equipment (oven, DC drive, etc) Overhead power supply Connection/disconnection of a bank of power factor correction capacitors Connecting power factor correction capacitors in parallel on the drive power supply line when the drive is running can generate transient overvoltages that are likely to trip the drive safety devices, or even damage it in etreme cases. If banks of power factor correction capacitors are used on the power supply line, make sure that: The threshold between steps is low enough to avoid causing overvoltage on the line The capacitors are not permanently connected Presence of commutation notches on the line When high-power thyristor-controlled equipment is connected on the same line as the drive, it is essential to ensure that the harmonics generated by the commutation notches do not ecessively distort the mains voltage and do not create voltage peaks with amplitude higher than 1.6 mains Vrms. If this is the case, it is essential to take corrective measures to guarantee the mains quality. 14

15 Unbalanced power supply In the same way as can be seen on an electric motor, the line voltage imbalance of a drive can have consequences on its operation. Please refer to the drive installation manual. Equipotential bonding The equipotential earth bonding of some industrial sites is not always observed. This lack of equipotentiality leads to leakage currents which flow via the earth cables (green/yellow), the machine frame, the pipework, etc and also via the electrical equipment. In some etreme cases, these currents can trip the drive. It is essential that the earth network is designed and implemented by the installation supervisor so that its impedance is as low as possible, so as to distribute the fault currents and high-frequency currents without them passing through electrical equipment. Metal grounds must be mechanically connected to each other with the largest possible electrical contact area. Under no circumstances can earth connections designed to protect people, by linking metal grounds to earth via a cable, serve as a substitute for ground connections (see IEC ). The immunity and radio-frequency emission level are directly linked to the quality of the ground connections Good wiring practice It is the responsibility of the user and/or the installer to connect the variable speed drive system in accordance with the current legislation and regulations in the country of use. This is particularly important as concerns cable size and connection of earths and grounds Power connections The following information is given for guidance only, and should never be used as a substitute for the current standards, nor does it relieve the installation company of their responsibility. For more information, please refer to technical specification IEC To ensure the safety of personnel, the size of the earthing cables should be determined individually in accordance with local regulations. For compliance with standard EN , the power conductors between drive and motor must be shielded. Use a special variable speed cable: shielded with low stray capacity and with 3 protective earth (PE) conductors arranged at 120 (diagram below). There is no need to shield the drive power supply cables. PE U PE The variable speed drive wiring must be symmetrical (U,V,W at the motor end must correspond to U,V,W at the drive end) with the cable shielding earthed at both the drive end and motor end over 360. When the installation complies with the emissions standard EMC category C2 (if an HV/LV transformer belongs to the user), the shielded motor power supply cable can be replaced with a 3-core + earth cable placed in a fully-enclosed metal conduit (metal cable duct for eample). This metal conduit must be mechanically connected to the electrical cabinet and the structure supporting the motor. If the conduit consists of several pieces, these should be interconnected by braids to ensure earth continuity. The cables must be fied securely at the bottom of the conduit. The motor earth terminal (PE) must be connected directly to the drive earth terminal. A separate PE protective conductor is mandatory if the conductivity of the cable shielding is less than 50% of the conductivity of the phase conductor Connecting the drive control cable and encoder cable shielding WARNING: Strip back the shielding on the metal clamp collars in order to ensure 360 contact. Connection to the drive Shielding connected to the 0V Shielded twisted pairs Cable shielding Metal clamp collars on the shielding Shielded twisted pairs Shielding connected to the 0V W V PE Scu Connection to the motor 15

16 Typical variable speed drive installation The following information is given for guidance only, and should never be used as a substitute for the current standards, nor does it relieve the installer of their responsibility. Depending on the installation, more optional elements can be added to the installation: Switch-fuse: a padlockable breaking device must be installed to isolate the installation if operator intervention becomes necessary. This device must provide protection against overheating and short-circuits. The fuse rating is stated in the drive documentation. The switchfuse can be replaced with a circuit-breaker (with appropriate breaking capacity). RFI filter: Its role is to reduce the drive electromagnetic emissions, and thus comply with EMC standards. Our drives are, as standard, equipped with an internal RFI filter. Some environments require the addition of an eternal filter. Please consult the drive documentation to find out the drive conformance levels, with and without an eternal RFI filter. Drive power supply cables: These cables do not necessarily need shielding. Their cross-section is recommended in the drive documentation, however, it can be adapted according to the type of cable, installation method, cable length (voltage drop), etc. Line reactance: Its role is to reduce the risk of damage to drives following phase imbalance or significant disturbance on the electrical mains supply. The line reactance can also reduce low-frequency harmonics. Motor power supply cables: These cables must be shielded to ensure EMC conformance of the installation. The cable shielding must be connected over 360 at both ends. At the motor end, special EMC cable glands are available as an option. The cable cross-section is recommended in the drive documentation, however, it can be adapted according to the type of cable, installation method, cable length (voltage drop), etc. Encoder cables: The sensor cable shielding is important due to interference with the power cables. This cable must be laid at least 30 cm away from any power cables. Sizing the power cables: The drive and motor power supply cables must be sized according to the applicable standard, and according to the design current stated in the drive documentation. The different factors to be taken into account are: - The installation method: in a conduit, a cable tray, suspended, etc - The type of conductor: copper or aluminium Once the cable cross-section has been determined, check the voltage drop at the motor terminals. A significant voltage drop results in increased current and additional losses in the motor (temperature rise). Equipotential bonding between the frame, motor, drive, transformer and earth carried out in accordance with good practice will significantly help reduce the voltage on the shaft and the motor casing, resulting in fewer high-frequency leakage currents. Premature breakage of bearings and auiliary equipment, such as encoders, should also be avoided wherever possible. Mains supply PE Optional RFI filter PE Optional line reactance L1 L2 L3 PE EMERSON DRIVE U V W PE Switch-fuse Encoder cable Optional encoder HF flat braid (see section ) 16

17 Terminal bo Located as standard on the top of the motor near the drive end, for mounting IM B3 and B5, the terminal bo is IP55 protected. WARNING: The position of the terminal bo cannot be easily modified, even with flanged motors, as the condensation drain holes must be at the bottom. Using a cable gland (NFC and 312 standards) If the position of the cable gland has not been correctly specified on the order, or is no longer suitable, the symmetrical construction of the terminal bo enables it to be turned round in positions 1 and 3. A cable gland must never open upwards. Check that the incoming cable bend radius prevents water entering via the cable gland. A Standard position Standard position Motors are supplied as standard with terminal boes pre-drilled and threaded without cable glands or removable undrilled cable gland support plate depending on the types of motor. Tightening capacity of cable glands (NFC and 312 standards) Adapt the cable gland and its reducer, if fitted, to the diameter of the cable being used. In order to maintain the motor's original IP55 protection, it is essential to ensure the cable gland provides a total seal by tightening it correctly (so that it cannot be unscrewed by hand). When there are several cable glands and some are not being used, ensure that they are always covered and tighten them so that they also cannot be unscrewed by hand. Ø min. Ø ma. Type and cable size of cable glands Type of cable gland Min. cable Ø (mm) Cable size Ma. cable Ø (mm) ISO ISO ISO ISO ISO ISO ISO In certain applications, there must be earth continuity between the cable and the motor earth to ensure protection of the installation in accordance with the EMC directive, 89/336/EEC. A cable gland option with anchorage on armoured cable is therefore available across the whole range of synchronous motors with magnets Power supply cable cross-sections The higher the current, the greater the voltage drop in the cables (standard NFC or end user's national standard). The voltage drop must therefore be calculated for the motor rated current indicated on the nameplate and acceptance will depend on the application and the type of cable. 17

18 Motor connections Motors Frame size 160 U1 V1 W1 U V W To the drive Connecting the power supply cables to the terminal block The cables must be fitted with connectors suitable for the cable cross-section and the terminal diameter. They must be crimped in accordance with the connector supplier's instructions. They must be connected with connector resting on connector (see diagrams below): Frame size > 160 U1-2 V1-2 W1-2 U1-1 V1-1 W1-1 U V W To the drive Do not change the positioning bars, they are not coupling links. To reverse the direction of rotation, refer to the manual for the corresponding drive. WARNING: For motors with backstop: starting in the wrong direction destroys the backstop (see arrow on motor housing) Earth terminal This is located inside the terminal bo. In some cases, the earth terminal is located on one of the feet or one of the cooling fins (round motors). It is indicated by the symbol: The motor housing must be connected to the frame earth via a high-frequency flat braid. It is compulsory to connect the motor to earth, and earthing must be performed in accordance with current regulations (protection of workers). Eample of connecting the motor earth to the frame: Size of terminal block nuts: Motors with frame size 160 Frame size Speed (min -1 ) Terminals 90 all M5 100 and 132 all M6 160 N 2400 M6 N > 2400 M8 Motors with frame size 200 Motor current (A) Terminals 63 M6 63 < I 125 M < I 320 M12 I > 320 M16 Tightening torque (N.m) on the terminal block nuts Terminal M4 M5 M6 M8 M10 M12 M14 M16 Steel 2 3, Brass If using cables without connectors, attach some calipers. If any nuts on the brass terminal block are lost, they must be replaced by brass nuts, not steel ones. When closing the bo, ensure that the seal is correctly positioned. As a general rule, check that no nut, washer or other foreign body has fallen into or come into contact with the winding. HF flat braid 18

19 Forced ventilation option 230 or 400 V SINGLE-PHASE FORCED VENTILATION for frame size 132 THREE-PHASE FORCED VENTILATION for frame size > 132 Blue Brown U Z CP1 Motor type LS 90 to 132 Capacitors CP1 CP2 3 mf 2 mf W2 U2 V2 1 SPEED - 2 VOLTAGES L1 - L2 - L3 230 V 400 V W2 U2 V2 Black W V U = 230 V U = 400 V Power supply on U and W Power supply on V and W U1 V1 W1 U1 V1 W1 CP2 L1 L2 L3 L1 L2 L Protection devices If the motor is fitted with accessories (thermal protection and/or space heater), these should be connected on screw dominos or terminal blocks with labelled wires (see section 3.4). Sensor 19

20 Encoder connections Connecting with feedback via standard incremental encoder with commutation channels, controlled by a Powerdrive MD2 or Powerdrive FX drive 20 Encoder with commutation channels (1) LSRPM 17-pin connector on encoder end (male plug) No. Wire Designation White/green White/pink White/yellow White/blue White/grey White/brown Green Grey Red Pink Yellow Blue Brown White R U\ V V\ W W\ A C or O or Z C\ or O\ or Z\ A\ B B\ +5V or +15V 0V Shielding (2) MDX-Encoder terminal block (3) Designation R U\ V V\ W W\ A A\ B B\ + _ MDX-ENCODER (3) - + A A B B O O T1T2 U U V V W W The thermal sensor located in the motor terminal bo should be connected to terminals T1, T2 of the MDX-ENCOD- ER option (refer to the drive manuals). (1) Encoder references KH05 and KHK5S are fitted as standard on Dyneo motors. (2) Use shielded cable on each pair (U,U\), (V,V\), (W,W\) etc. Connect the shielding 360 round the connector. (3) Powerdrive MD2 and FX option used to manage the motor speed feedback Connecting with feedback via standard incremental encoder with commutation channels, controlled by a Unidrive M700/701/702 drive Encoder with commutation channels (1) LSRPM No pin connector on encoder end (male plug) Wire White/green White/pink White/yellow White/blue White/grey White/brown Green Grey Red Pink Yellow Blue Brown White Designation R U\ V V\ W W\ A C or O or Z C\ or O\ or Z\ A\ B B\ +5V or +15V 0V Shielding (2) 15-pin connector on drive end Pr AB.Servo No (3) The thermal sensor located in the motor terminal bo should be connected to terminals 8 and 11 on the drive control terminal block. To modify sensor control, see parameter 7.15 (0.21). (1) Encoder references KH05 and KHK5S are fitted as standard on Dyneo motors. (2) Use shielded cable on each pair (U,U\), (V,V\), (W,W\). Connect the shielding 360 round the connector. (3) Connect the shielding 360 round the drive shielding holder.

21 4 - COMMISSIONING THE VARIABLE SPEED DRIVE For information on how to start up the motor-drive system, refer to the manual for the drive used. Quick commissioning is described according to the operating mode chosen (with sensor or sensorless). 5 - ROUTINE MAINTENANCE Checks Running-in the bearings for series 4500 and 5500 When the motor is commissioned, and each time the bearings are replaced, the bearings must be run-in to obtain optimum service life. Set the rotation speed to 4000 min-1, then each time the bearing temperature stabilizes, increase the speed by 500 min-1 up to maimum speed. During this period, check that the bearing temperature remains below 110 C. Checks during start-up Check: - noise - vibration - operation of the buttons/switches - also check the current and voltage on the machine while it is operating with the rated load Checks after approimately 50 hours operation Check: - that the screws fiing the motor and the coupling device are correctly tightened - in the case of chain or belt transmission, check that the tension is correctly adjusted Cleaning To ensure the motor operates correctly, remove any dust or foreign bodies which might clog the cover grille and the housing fins. Precaution: before carrying out any cleaning operation, check that the motor is totally sealed (terminal bo, drain holes, etc). Dry cleaning (vacuuming or compressed air) is always preferable to wet cleaning. Always clean at reduced pressure from the centre of the motor outwards to avoid introducing dust and particles under the seals. Draining condensation water Temperature variations cause condensation to form inside the motor, which must be removed before it adversely affects motor operation. Condensation drain holes located at the bottom of the motors (bearing in mind their operating position) are sealed with plugs which must be removed and then replaced every si months (if they were not replaced, the motor degree of protection would no longer be maintained). Clean the holes and plugs before reassembly. Note: In conditions of high humidity and significant temperature variations, a shorter period is recommended. As long as there is no risk for the motor protection, the condensation drain plugs can be removed. Annual checks Check: - that the screws fiing the motor are correctly tightened - the electrical connections - vibration 21

22 5.2 - Bearings and lubrication Types of bearing The bearings are defined in accordance with the table below: Voltage Speed (min -1 ) Power (kw) NDE bearing DE bearing N 900 All Standard < 160 Standard 900 < N Insulated outer ring Standard < 460 V 460 V 2400 < N < N 4500 N > 4500 < 145 Standard 145 P < 325 Insulated 325 outer ring Standard Insulated outer ring < 55 Standard Standard 55 Insulated outer ring Insulated outer ring < 55 Standard Standard Insulated Insulated 55 ceramic ceramic balls balls N 900 All Standard Standard < 55 Standard Standard N > Insulated ceramic balls Standard + earth ring Type of grease When the bearings are not greased for life, the type of grease is indicated on the nameplate. The frequency of lubrication and the quantity and quality of grease are given on the nameplates. Refer to these to ensure correct bearing lubrication. Even in the event of prolonged storage or downtime, the interval between 2 greasing operations must never eceed 2 years Bearing maintenance As soon as you detect any of the following on the motor: - abnormal noise or vibration - abnormal temperature rise in the bearing when it is correctly greased, the state of the bearings must be checked. Damaged bearings must be replaced as soon as possible to prevent worse damage to the motor and the equipment being driven. When one bearing needs to be replaced, the other bearing must also be replaced. The seals should be changed routinely when the bearings are changed. The free bearing must allow the rotor shaft to epand (check its identification during dismantling). Avoid miing greases. FS Speed (min -1 ) < 225 All 225 N 3600 N > 3600 Lubrication type Permanently greased bearings Bearings with grease nipples Bearings with grease nipples Grease ENS, WT or BQ Polyre EM 103 BQ Permanently greased bearings Under normal operating conditions, the service life (L10h) of the lubricant is 25,000 hours for a machine installed horizontally and for temperatures less than 25 C Bearings with grease nipples The bearings are lubricated in the factory The end shields are fitted with bearings lubricated by Técalémit grease nipples. 22

23 6 - PREVENTIVE MAINTENANCE Consult LEROY-SOMER, who in its continuous search for ways to help our customers, has evaluated numerous methods of preventive maintenance. The diagram and table below give the recommended equipment to use and the ideal positions to take measurements of all parameters which can affect the operation of the machine, such as eccentricity, vibration, state of the bearings, structural problems, electrical problems, etc. 3 1 M 01V E01 E02E03 M 02V M 02A M 01H M 02H Detector Measurement Measurement points M 01V M 01H M 02V M 02H M 02A Shaft E01 E02 E Accelerometer For measuring vibrations 2 - Photo-electric cell For measuring speed 3 - Clamp ammeter For measuring current (DC or 3-phase AC) 4 - Voltage probe For measuring voltages 5 - Infra-red probe For measuring temperature 23